Method for manufacturing a coated cellulosic substrate and a coated cellulosic substrate

Abstract

A method for manufacturing a coated cellulosic substrate including delivering a blended starch composition to a metering size press and applying a coating of the blended starch composition from the metering size press onto a cellulosic substrate. The blended starch composition includes a lipophobic starch having a shear-thinning rheology and a food grade starch.

1 . A method for manufacturing a coated cellulosic substrate, the method comprising:
 delivering a blended starch composition to a metering size press, the blended starch composition comprising:
 a lipophobic starch having a shear-thinning rheology, and 
 a food grade starch; and 
   applying a coating of the blended starch composition from the metering size press onto a cellulosic substrate.   
     
     
         2 . The method of  claim 1 , wherein the cellulosic substrate has a basis weight in a range of from about 16 to about 36 pounds per 1000 square feet. 
     
     
         3 . The method of  claim 1 , wherein the cellulosic substrate has a basis weight in a range of from about 21 to about 31 pounds per 1000 square feet. 
     
     
         4 . The method of  claim 1 , wherein the cellulosic substrate has a basis weight in a range of from about 24 to about 28 pounds per 1000 square feet. 
     
     
         5 . (canceled) 
     
     
         6 . The method of  claim 1 , wherein the cellulosic substrate has a Gurley porosity in a range of from about 5 seconds per 100 cubic centimeters to about 200 seconds per 100 cubic centimeters. 
     
     
         7 . The method of  claim 1 , wherein the cellulosic substrate has a Gurley porosity in a range of from about 10 seconds per 100 cubic centimeters to about 150 seconds per 100 cubic centimeters. 
     
     
         8 . (canceled) 
     
     
         9 . The method of  claim 1 , wherein a weight ratio of the lipophobic starch to the food grade starch is in a range of from about 1:99 to about 99:1. 
     
     
         10 . The method of  claim 1 , wherein a weight ratio of the lipophobic starch to the food grade starch is in a range of from about 30:70 to about 98:2. 
     
     
         11 . The method of  claim 1 , wherein a weight ratio of the lipophobic starch to the food grade starch is in a range of from about 40:60 to about 95:5. 
     
     
         12 - 14 . (canceled) 
     
     
         15 . The method of  claim 1 , wherein the food grade starch has a water fluidity in a range of from about 1 to about 80. 
     
     
         16 . The method of  claim 1 , wherein the food grade starch has a water fluidity in a range of from about 5 to about 70. 
     
     
         17 . The method of  claim 1 , wherein the food grade starch has a water fluidity in a range of from about 10 to about 60. 
     
     
         18 - 19 . (canceled) 
     
     
         20 . The method of  claim 1 , wherein the blended starch composition has a solids content in a range of from about 17% to about 40%. 
     
     
         21 . The method of  claim 1 , wherein the blended starch composition has a solids content in a range of from about 20% to about 28%. 
     
     
         22 . The method of  claim 1 , wherein the blended starch composition has a solids content in a range of from about 22% to about 26%. 
     
     
         23 . (canceled) 
     
     
         24 . The method of  claim 1 , wherein the coating has a dry coat weight in a range of from about 1.0 g/m 2  to about 10.0 g/m 2 . 
     
     
         25 . The method of  claim 1 , wherein the coating has a dry coat weight in a range of from about 2.0 g/m 2  to about 8.0 g/m 2 . 
     
     
         26 - 27 . (canceled) 
     
     
         28 . The method of  claim 1 , wherein the shear-thinning rheology of the lipophobic starch allows the blended starch coating to become thinner as the blended starch coating is driven under high shear into a nip of the metering size press but then regain viscosity as blended starch coating flows away from the nip, which serves to reduce starch penetration into the cellulosic substrate to ensure that the lipophobic starch predominantly remains at the surface of the cellulosic substrate to ensure sufficient oil and grease resistance. 
     
     
         29 . A method for manufacturing a coated cellulosic substrate, the method comprising:
 delivering a blended starch composition to a metering size press, the blended starch composition comprising:
 a lipophobic starch having a shear-thinning rheology, and 
 a food grade starch having a water fluidity in a range of from about 1 to about 80, 
 wherein a weight ratio of the lipophobic starch to the food grade starch is in a range of from about 1:99 to about 99:1, and 
 wherein the blended starch composition has a solids content in a range of from about 17% to about 40%; and 
   applying a coating of the blended starch composition from the metering size press onto a cellulosic substrate to achieve a dry coat weight in a range of from about 1.0 g/m 2  to about 9.0 g/m 2 , wherein the cellulosic substrate has a basis weight in a range of from about 16 to about 69 pounds per 1000 square feet and a Gurley porosity in a range of from about 5 seconds per 100 cubic centimeters to about 200 seconds per 100 cubic centimeters.   
     
     
         30 . A coated cellulosic substrate, comprising:
 a cellulosic substrate; and   a blended starch coating on the cellulosic substrate, the blended starch coating comprising a lipophobic starch and a food grade starch.   
     
     
         31 - 54 . (canceled)